neat idea. I've considered and tried something similar myself. think a detailed 'tron'. Though I found the biggest problem is the seams. To make a circuit board photo line up correctly would be a real time consuming job. English Bobs neat picture would make life a lot easier, but you'd have to be really carefull on areas like the shoulders. I found when making the vorg series of maps the easiest soultion was to make the circuited areas fade into black. It's in freestuff here, download it and have a close look at the edges and it might help you.

Pinky - you left the lens cap of your mind on again.